CXL ParallelThread Couplersfor the Construction Industry

CI/SfB (29) Et6

June 2015

International Version

Characteristic Strengths of High YieldReinforcing BarDiameter Area Fy(kN)(mm) (mm2) 500N/mm2

12 113 56.5

16 201 100.5

20 314 157.0

22 380 190.0

25 491 245.5

28 616 307.8

32 804 402.1

36 1,018 509.0

40 1,256 628.3

50 1,963 981.7

Ancon couplers can simplify the design andconstruction of reinforced concrete and reducethe amount of reinforcement required.

Lapped joints are dependent upon theconcrete for load transfer. For this reason anydegradation in the integrity of the concretecould significantly affect the performance ofthe joint. The strength of a mechanical splice isindependent of the concrete in which it islocated and will retain its strength despite lossof cover as a result of impact damage orseismic event.

The Ancon range of reinforcing bar couplers isthe most comprehensive available andincludes tapered threaded, parallel threadedand mechanically bolted couplers.

2 Tel: +44 (0) 114 275 5224 www.ancon.co.uk

Eurocode 2 compliant Simplify design andconstruction

Reduce amount ofreinforcement required

Dedicated salessupport

Available throughAncon approveddistributors andrebar fabricators

ISO 9001, ISO 14001,OHSAS 18001

Lapped joints are not always anappropriate means of connectingreinforcing bars. The use of lapscan be time consuming in termsof design and installation andcan lead to greater congestionwithin the concrete because ofthe increased amount of rebarused.

Reinforcing Bar Couplers

The end of each bar tobe joined is cut squareand enlarged by coldforging. This increases

the core diameter of the bar to ensure that thejoint is stronger than the bar.

Parallel metric threads are cut onto theenlarged ends. The threaded end is then prooftested to a force equal to the characteristicyield strength of the bar. A nominal allowanceof +50mm per threaded bar end should bemade for cutting square and cold forging.

CXL Type BThe CXL Type B uses the same coupler as theType A system, but one bar is threaded for afull coupler length. It is used for applicationswhere it is difficult but not impossible to rotatethe continuation bar.

CXL Type CThe CXL Type C system has an additionallocknut and is used where the continuation barcannot be rotated. The continuation bar isthreaded for the full coupler length plus thelength of the locknut.

CXL Type AThe CXL Type A system utilises internallythreaded couplers with a single right handthread and is suitable for applications wherethe continuation bar can be rotated. The endsof the bars are upset and threaded for half thelength of the coupler.

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CXL Dimensions

2tt

t

t2t

2/3 t2 2/3 t

2tt

2t

The threaded ends of the bars are protected byan external plastic sheath. Couplers, which areusually supplied attached to the bar, have theirinternal threads protected by an internal plasticend cap. For certain applications, especiallywhere CXL is being used in deep pours,

the coupler end caps may not prevent theingress of concrete fines. For these applications,further protection may be required.

CXL couplers are also available to join barsof different diameters. For further informationplease contact Ancon Building Products.

Bar Diameter (mm) 12 16 20 22 25 28 32 36 40 50

External Dia. (mm) d 22 30 35 36 42 48 55 60 65 80

Coupler Length (mm) l 28 40 48 52 60 66 72 84 90 112

Thread Size (mm) M16 M20 M24 M26 M30 M33 M36 M42 M45 M56

Thread Pitch 2.0 2.5 3.0 3.0 3.5 3.5 4.0 4.5 4.5 5.5

Weight (kg) 0.04 0.09 0.16 0.22 0.32 0.43 0.58 0.87 1.13 2.17

Part No Type A CXL12/A CXL16/A CXL20/A CXL22/A CXL25/A CXL28/A CXL32/A CXL36/A CXL40/A CXL50/A

Part No Type B CXL12/B CXL16/B CXL20/B CXL22/B CXL25/B CXL28/B CXL32/B CXL36/B CXL40/B CXL50/B

Part No Type C - CXL16/C CXL20/C CXL22/C CXL25/C CXL28/C CXL32/C CXL36/C CXL40/C CXL50/C

CXLCXL couplers produce a full strength joint yet they are among the smallest in the Ancon range,best suited to large scale projects requiring a high volume of couplers.

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Nominal Yield Ultimate Elongation FailureBar Size Stress Stress % ModeDia. (mm) (N/mm2) (N/mm2)

16 531 587 18 Bar Break

20 518 596 20 Bar Break

25 522 625 18 Bar Break

32 484 604 20 Bar Break

40 512 629 18 Bar Break

50 510 669 17 Bar Break

Two Stage ConstructionIn two stage construction utilising Types B andC couplers, it is essential to form a pocket inthe face of the first stage concrete. This willcreate the space for the coupler to run onto thethread of the fixed reinforcing bar.

A pocket former is screwed onto the end of thebar and cast flush with the face of the concrete.

Mobile Bar End Preparation FacilityCXL threading equipment is generallyestablished in the rebar supplier’s premisesand couplers are usually supplied pre-fixed tothe threaded bar ends.

On large contracts where bar end preparationcan be carried out on site, equipment can bemade available for hire. It should be noted that the hirer will need to provide sufficientpower, air, rebar support tressles and cranehandling facilities.

Testing & ApprovalsCXL couplers are designed andmanufactured in accordance withBS EN ISO 9001 and comply in all respectsto BS EN 1992-1-1:2004 (Eurocode 2) andBS 8110 when used with reinforcing bar toBS 4449. Tests have been carried out toshow compliance with Russia CodeRD-EO 0657-2006 and independentapprovals, ITB Approval No. AT-15-9037/2013,BRI NI SI EOOD Approval No. 118-214/09082011, DCL Approval No. TAC 132.

Typical Test Results

Reinforcing Bar Couplers

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InstallationThe CXL Type A System

Position the continuation bar with the coupleragainst the end of the first bar.

Rotate the coupler from the continuation bar toengage against the rear of the thread on theopposing bar and lock tight.

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The CXL Type B System

Screw the coupler to the rear of the thread onthe continuation bar.

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Using a wrench, rotate the continuation bar to lock the two bar ends against each other within thecoupler. After tightening, the length of exposed thread should be no more than half of the couplerlength plus 2-4mm depending on the diameter of the rebar.

Screw the coupler to the rear of the thread onthe fixed bar and lock tight. The bar endshould be central within the coupler.

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Remove the plastic cap from the coupler.Position and rotate the continuation bar in the coupler.

Tighten the joint using a wrench on thecontinuation bar. After tightening there shouldbe no more than 2-4mm of thread exposed,depending on the diameter of the rebar.

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Position the continuation bar with the coupleragainst the end of the first bar.

Rotate the coupler from the continuation bar toengage against the rear of the thread on theopposing bar and lock tight.

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The CXL Type C System

Screw the locknut followed by the coupler tothe rear of the thread on the continuation bar.

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Rotate the locknut along the continuation bar to abut the coupler.

Hold the rebar in its required orientation and with a wrench tighten the locknut against the coupler.

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Reinforcing Bar Couplers

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Anchorage of reinforcement within a concretesection is traditionally achieved by means ofcreating a long hooked end to the bar. Thesehooks can lead to problems when positioningthe bar and can increase congestion. This canultimately result in larger than necessaryconcrete sections at the location of hookedends.

The CXL Headed Anchor is essentially anoversized coupler capable of carrying the fulltension load of the bar when it bears againstthe concrete in which it is cast. The HeadedAnchor removes the need for the hooked rebarend and can subsequently reduce congestion,simplifying bar placement. This in turn increasesthe speed of construction and gives greaterflexibility in design. Typical applications includepile caps and beam-to-column connections.

To attach the Headed Anchor to the rebar, it isfirst necessary to enlarge the bar end and thenform the thread on the enlarged bar end usinga thread cutting machine. As with the CXLcoupler connection, the thread is such that thecross-sectional area of the bar end is notreduced, thus ensuring the tensile strength ofthe connection matches or exceeds that of theparent bar.

Concrete StrengthWhen the above sizes of CXL Headed Anchors are used, the compressive strength of theconcrete shall not be less than strength grade C32/40 (cylinder/cube). Where a lower concretestress is required, Headed Anchors can be supplied to a larger diameter to suit the specificapplication.

CXL Headed Anchor

CXL Headed AnchorThe Ancon CXL Headed Anchor provides an effective and proven method of achieving rebar endanchorage within concrete.

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Bar Diameter (mm) 16 20 25 32 40External Diameter (mm) d 52 65 80 110 135Anchor Thickness (mm) l 20 24 30 36 45Thread Size M20 M24 M30 M36 M45Anchor Weight (kg) 0.27 0.56 1.03 2.43 4.55Header Anchor Reference CXL16HA CXL20HA CXL25HA CXL32HA CXL40HAOther sizes are available on request. Contact Ancon for more details.

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Reinforcing Bar Couplers

The coupler is suitable for welding to structural steels EN BS 10025, Grade S275 (43A) orGrade S355 (Grade 50B), however the load conditions at the connection must be determinedby the designer responsible for the structural element, along with the type and size of weldrequired.

Other important considerations include the type of electrode to be used, which must bematched to the properties of the plate and tube, and to the site conditions under which thewelding will be undertaken. Welders should be qualified for the type of weld required.

As a minimum standard, welding of the couplers shall be in accordance with the guidanceprovided in the following documents:

BS EN ISO 15614-1:2004+A2:2012 Specification and qualification of welding proceduresfor metallic materials. Welding procedure test. Arc andgas welding of steels and arc welding of nickel andnickel alloys

BS EN 287-1 Qualification test of welders, Fusion welding, Steels

BS EN 9606-1:2013 Qualification testing of welders, Fusion welding, Steels

BS EN ISO 15607:2003 Specification and qualification of welding proceduresfor metallic materials. General rules BS EN ISO 15609-1:2004 Specification and qualification of weldingprocedures for metallic materials. Welding procedurespecification. Arc welding

BS EN 1011-1: 2009 Welding. Recommendations for welding of metallic materials.General guidance for arc welding

BS EN 1011-2:2001 Welding. Recommendations for welding of metallic materials.Arc welding of ferritic steels

CXL Welded Couplers are manufactured from either Steel Grade 1045 to ASTM A576 orSteel Grade C45R to EN10083.

Carbon Equivalent Value - The Carbon Equivalent value of these couplers may typically varybetween 0.50 - 0.75, where the carbon equivalent value is given by CEV = C + (Mn)/6 + (Ni+Cu)/15 +(Cr+Mo+V)/5

CXL Welded Couplers

The coupler must first be welded to thesteelwork.

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Rotate the bar into the coupler until tight.

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InstallationCXL Weldable Couplers

When ready to extend, remove the plastic end cap and position the continuation bar intothe sleeve.

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Tighten the continuation bar using a wrench.Bar Diameter (mm) 16 20 25 32 40Coupler Diameter (mm) d 33 38 48 57 72Coupler Length (mm) l 40 48 60 72 90Thread Size M20 M24 M30 M36 M45Weld Preparation (mm) p 5.5 5.0 5.5 11.0 12.5Coupler Weight (kg) 0.18 0.30 0.58 0.96 1.91Coupler Reference CXL16W CXL20W CXL25W CXL32W CXL40W

CXL welded couplers provide a convenient means of connecting reinforcing bars to structural steel plates orsections. One end is internally threaded with the CXL thread form; the other end is prepared for welding to the steel.

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CXL Weldable Couplers

Other Ancon ProductsReinforcement Continuity SystemsReinforcement Continuity Systems are an increasingly popular means of maintaining continuity ofreinforcement at construction joints in concrete. The Ancon Eazistrip re-bend system is approvedby UK CARES and consists of pre-bent bars housed within a galvanised steel casing. Onceinstalled, the bars are straightened ready for lapping with slab reinforcement. Ancon KSN Anchorsand Ancon Starter Bars are cast into a concrete wall and accept threaded continuation bars. Theyeasily accommodate long EC2 lap lengths and eliminate the need for on-site bar straightening.KSN Anchors minimise rebar congestion in the wall.

Shear Load ConnectorsAncon DSD and ESD Shear Load Connectors are used to transfer shear across expansion andcontraction joints in concrete. They are more effective at transferring load and allowing movementto take place than standard dowels. The range features rectangular box section sleeves to allowlateral movement in addition to longitudinal movement. A range of Lockable Dowels is available fortemporary movement joints in post-tensioned concrete.

Channel and Bolt FixingsAncon offers a wide range of channels and bolts in order to fix stainless steel masonry support,restraints and windposts to structural frames. Cast-in channels and expansion bolts are used forfixing to the edges of concrete floors and beams.

Punching Shear ReinforcementAncon Shearfix is used within a slab to provide additional reinforcement from punching sheararound columns. The system is approved by UK CARES and consists of double-headed steelstuds welded to flat rails. Shearfix is designed to suit the load conditions and slab depth at eachcolumn using free calculation software from Ancon.

Insulated Balcony ConnectionsAncon’s thermally insulated connectors minimise heat loss at balcony locations while maintainingstructural integrity. They provide a thermal break and, as a critical structural component, transfermoment, shear, tension and compression forces. Standard solutions are available for concrete-to-concrete, steel-to-concrete and steel-to-steel interfaces.

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© Ancon Building Products 2014

These products are available from:

Masonry Support Systems

Lintels

Masonry Reinforcement

Windposts and Parapet Posts

Wall Ties and Restraint Fixings

Channel and Bolt Fixings

Tension and Compression Systems

Insulated Balcony Connectors

Shear Load Connectors

Punching Shear Reinforcement

Reinforcing Bar Couplers

Reinforcement Continuity Systems

Stainless Steel Fabrications

Flooring and Formed Sections

Refractory Fixings

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The construction applications and details provided in this literature are indicative only. In every case, project workingdetails should be entrusted to appropriately qualified and experienced persons.

Whilst every care has been exercised in the preparation of this document to ensure that any advice, recommendations orinformation is accurate, no liability or responsibility of any kind is accepted in respect of Ancon Building Products.

With a policy of continuous product development Ancon Building Products reserves the right to modify product designand specification without due notice.